Efficient Prediction and Real-time Compensation of Milling Force-induced Error in Thin-walled Parts Based on Stiffness Reduction and Local Update

doi:10.3901/JME.2025.17.331

Abstract

Abstract: Aerospace thin-walled parts are prone to machining errors under the action of milling forces due to their complex structures, weak stiffness, and high material removal rates. Machining process optimization and the finite element method provide effective means to solve this problem, but issues such as high economic costs and long computation time still exist. Therefore, an efficient prediction and real-time compensation method for milling force-induced errors in thin-walled parts is proposed. Firstly, to address the large computational load of the finite element method when considering the material removal effect, an efficient prediction method based on stiffness reduction and local update is established. Furthermore, an error compensation value calculation method based on iterative coefficients is proposed to decrease the deviation between the actual and ideal compensation amounts caused by tool-workpiece elastic deformation. Finally, a thin-walled blade milling experiment is carried out. The experiment results revealed that the prediction time for compensation value is decreased by 45.9% compared to finite element methods, and the machining error is reduced by 58.3% after compensation, effectively improving its computation efficiency and machining accuracy.

Key words: thin-walled parts, milling, error modelling, stiffness matrix, real-time compensation

CLC Number:

TH164

GE Guangyan, XIAO Yukun, Lü Jun, DU Zhengchun. Efficient Prediction and Real-time Compensation of Milling Force-induced Error in Thin-walled Parts Based on Stiffness Reduction and Local Update[J]. Journal of Mechanical Engineering, 2025, 61(17): 331-342.

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